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Metals
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Additive Manufacturing for Tooling Applications: Materials, Design, Processes & Impacts
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Additive Manufacturing for Tooling Applications: Materials, Design, Processes & Impacts

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: closed (10 January 2025) | Viewed by 10353

Special Issue Editor

Prof. Dr. Nader Asnafi

E-Mail
Guest Editor
1. Engineering Sciences and Mathematics, Luleå University of Technology, SE-971 87 Luleå, Sweden
2. Zhejiang Chuangge Technology Co. Ltd., No. 32 QianXi Road, Zhuji 311800, China
Interests: digital transformation; materials and technologies for a circular economy; development and operation/use of sustainable products and manufacturing systems
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM), an alternative to conventional manufacturing processes, is often considered a disruptive production method. However, it can also improve conventional manufacturing by providing a better way to produce and repair/remanufacture tools and enhance operational performance. Part manufacturers use tooling to make other parts which can, thus, incorporate AM into the production chain.

This Special Issue focuses on additive manufacturing for tooling applications. Topics of interest include, but are not limited to:

  • Materials, i.e., metal alloys, transition metals, semi-metals, metalloids, cermets, etc.;
  • The interaction (i.e., microstructure, properties, etc.) between studied/targeted materials and design, including the material design, tool (i.e., part) design (i.e., generative design, topology optimization, lattice structure, and surface optimization), and AM process design (i.e., design for additive manufacturing);
  • The consequences of studied material for tooling applications from powder atomization and AM to post-processing for toolmaking, tool repair and remanufacture, and tool surface treatment/functionalization from cyber-physically controlled processes and systems to quality assurance;
  • The advantages and/or disadvantages of the studied material and its tooling application for lead and cycle times, scrap rate, total costs, time to market, break-even points, material and energy usage, circularity in the economy, sustainability, etc.

Prof. Dr. Nader Asnafi
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing
  • tooling
  • material
  • design
  • processes
  • impacts
  • repair
  • remanufacture
  • efficient operational performance

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Published Papers (4 papers)

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Research

16 pages, 8188 KiB  
Article
Effect of Printing Orientation Angle and Heat Treatment on the Mechanical Properties and Microstructure of Binder-Jetting-Printed Parts in 17-4 PH Stainless Steel
by Iacopo Bianchi, Archimede Forcellese, Pietro Forcellese, Tommaso Mancia, Chiara Mignanelli, Michela Simoncini and Tommaso Verdini
Metals 2024, 14(11), 1220; https://doi.org/10.3390/met14111220 - 26 Oct 2024
Viewed by 3488
Abstract
The present work aims to study the effect of printing orientation angle and heat treatment on the mechanical properties and microstructure of 17-4 PH stainless steel 3D-printed parts obtained by the binder jetting process to assess the suitability of the process and material [...] Read more.
The present work aims to study the effect of printing orientation angle and heat treatment on the mechanical properties and microstructure of 17-4 PH stainless steel 3D-printed parts obtained by the binder jetting process to assess the suitability of the process and material for rapid tooling applications. To this purpose, tensile specimens were printed at different printing orientation angles (0°, 45°, and 90°). Half of the specimens were left in the as-sintered condition after the 3D-printing operation, while the other half of the specimens was subjected to H900 heat treatment. Then, tensile and hardness tests were performed to investigate the macro-mechanical properties as a function of the printing orientation angles and postprocessing thermal treatment. Scanning electron microscopy with energy dispersive X-ray spectroscopy was used to observe the fracture surfaces and microscopical defects on the binder jetting printed parts to evaluate the fracture mechanisms. It was demonstrated that printing orientation angles do not affect the mechanical properties of 3D-printed parts, while a significant improvement in the microstructure and mechanical properties is observed after the H900 heat treatment. Full article
(This article belongs to the Special Issue Additive Manufacturing for Tooling Applications: Materials, Design, Processes & Impacts)
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12 pages, 2801 KiB  
Article
Movement Strategy Influences on the Characteristics of Low-Carbon Steel Generated by the Lamination Object Manufacturing Method
by Tran Le Hong Ngoc, Ha Thi Xuan Chi, Pham Son Minh, Van-Thuc Nguyen and Tran Minh The Uyen
Metals 2024, 14(3), 356; https://doi.org/10.3390/met14030356 - 19 Mar 2024
Viewed by 1430
Abstract
This paper investigates the effects of heating movement techniques on the properties of low-carbon steel samples that are 3D printed using S20C lamination object manufacturing (LOM). A Tungsten iner gas (TIG) machine and a computer numerical control (CNC) machine were used together to [...] Read more.
This paper investigates the effects of heating movement techniques on the properties of low-carbon steel samples that are 3D printed using S20C lamination object manufacturing (LOM). A Tungsten iner gas (TIG) machine and a computer numerical control (CNC) machine were used together to join the steel sheet. The LOM samples were created with a straight-profile, short-profile, cross-profile, and curved-profile. The results indicate that the majority of the samples had a grain size number of 7–9. The samples exhibited an isotropy grain shape. The LOM samples exhibited dimples, which suggests ductility fractures. Pore flaws showed up in the microstructure of the cross-profile and short-profile samples during the LOM process. The samples with curved- and straight-profiles had a better microstructure. In comparison to samples with a short profile and a cross-profile, the samples with a straight-profile and a curved-profile had a superior combination of ultimate tensile strengths (UTSs) and elongation value. The straight- and curved-profiles’ greater elongation and tensile strength can be attributed to their improved microstructure and finer grain size. A straight-profile sample with an elongation value of 25.6% and a UTS value of 430 MPa was the ideal LOM sample. Conversely, the weakest sample was the LOM sample with a cross-profile, which had an elongation value of 10.8% and a UTS value of 332.5 MPa. This research could provide further information about the LOM method and the best straight-profile movement strategy. A suitable TIG gun movement strategy could produce a good LOM sample with a good microstructure, tensile strength, and ductility. Further research should incorporate more movement strategies and techniques that completely prevent the formation of pore defects. Full article
(This article belongs to the Special Issue Additive Manufacturing for Tooling Applications: Materials, Design, Processes & Impacts)
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13 pages, 5768 KiB  
Article
Effect of Different Post-Processing Thermal Treatments on the Fracture Toughness and Tempering Resistance of Additively Manufactured H13 Hot-Work Tool Steel
by Faraz Deirmina, Sasan Amirabdollahian, Massimo Pellizzari and Alberto Molinari
Metals 2024, 14(1), 112; https://doi.org/10.3390/met14010112 - 17 Jan 2024
Cited by 4 | Viewed by 2007
Abstract
Near-full density and crack-free AISI H13 hot-work tool steel was fabricated using laser-directed energy deposition (L-DED). Two different heat-treatment scenarios, i.e., direct tempering (ABT) from the as-built (AB) condition and systematization and quenching prior to tempering (QT), were investigated, and their effect on [...] Read more.
Near-full density and crack-free AISI H13 hot-work tool steel was fabricated using laser-directed energy deposition (L-DED). Two different heat-treatment scenarios, i.e., direct tempering (ABT) from the as-built (AB) condition and systematization and quenching prior to tempering (QT), were investigated, and their effect on the microstructure, hardness, fracture toughness (Kapp), and tempering resistance of the L-DED H13 is reported. For this purpose, the optimal austenitization schedule was identified, and tempering curves were produced. At a similar hardness level (500 HV1), QT parts showed higher Kapp (89 MPa√m) than ABT (70 MPa√m) levels. However, the fracture toughness values obtained for both parts were comparable to those of wrought H13. The slightly larger Kapp in the QT counterpart was discussed considering the microstructural homogenization and recrystallization taking place during high-temperature austenitization. The tempering resistance of the ABT material at 600 °C was slightly improved compared with that of the QT material, but for longer holding times (up to 40 h) and higher temperatures (650 °C), ABT showed superior resistance to thermal softening due to a finer martensite substructure (i.e., block size), a finer secondary carbide size, and a larger volume fraction of secondary V(C,N) carbides. Full article
(This article belongs to the Special Issue Additive Manufacturing for Tooling Applications: Materials, Design, Processes & Impacts)
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13 pages, 11952 KiB  
Article
Powder Injection Molding of Ti-Al-W Nano/Micro Bimodal Powders: Structure, Phase Composition and Oxidation Kinetics
by Maksim Krinitcyn, Alexander Pervikov, Dmitriy Kochuev and Marat Lerner
Metals 2022, 12(8), 1357; https://doi.org/10.3390/met12081357 - 15 Aug 2022
Cited by 2 | Viewed by 2057
Abstract
Products from the materials of the Ti-Al system are difficult to manufacture. This often restricts the use of such materials despite their outstanding properties. Some of the promising methods for manufacturing products, which allows working with materials of the Ti-Al system, are powder [...] Read more.
Products from the materials of the Ti-Al system are difficult to manufacture. This often restricts the use of such materials despite their outstanding properties. Some of the promising methods for manufacturing products, which allows working with materials of the Ti-Al system, are powder injection molding (PIM) and material extrusion additive manufacturing (MEAM) technologies. In the present study, powder composites Ti-48Al-4W with different powder size distribution, obtained by the electric explosion of wire (EEW) method, were investigated. The powder was used in PIM technology to produce bulk samples. After polymer debinding, PIM samples were sintered in a vacuum and using hot isostatic pressing (HIP) at the same temperatures and isothermal holding times. The results show the influence of size distribution and sintering method on the structure, phase composition, mechanical properties and oxidation resistance of pre-sintered PIM samples. It is found that both the size distribution and sintering method affect the mechanical properties. The smaller the particle size of the powder in the material, the greater the resistance to oxidation of such samples. Full article
(This article belongs to the Special Issue Additive Manufacturing for Tooling Applications: Materials, Design, Processes & Impacts)
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